TSB – 24-2317: 2022-2024 Ford Maverick Pickups May Rattle Over Rough Roads

[Gray Goose]

Mine was fine until the weather turned colder. It's a bit of nostalgia, I've heard the noise before. Spent many days in this 1970's beast where the rattles were much more prevalent. The cab would rub on the cowl, the glass panes would rub on the cab, etc etc. It doesn't bother me too much, I think I've built up a tolerance from years of running old Ag equipment.

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[Brixil]

2024 lariat with ~3,000 miles. Passenger dash rattle has been driving me bonkers. I've trimmed the upper windshield alignment pin, added foam throughout the A-pillar, tried various forms of playing cards, cardboard, and foam throughout the lower windshield and speaker grille to no avail.

My last attempt was focused on the passenger airbag light (with the fake screws) before calling it quits and assuming it was something buried in dash.

I guess this gives me another excuse to drive circles around the neighborhood testing.

 

[zen_]

I've noticed a rattle from somewhere in the passenger area, and where the dash plastic curves around the instrument panel. Thought about just fixing the instrument stuff myself with black foam, but maybe I should have this whole service done.

Pretty dumb question as this is the first new vehicle I've personally owned with a warranty, how do you go about scheduling services for TSBs that are applicable to your vehicle, and for ones like this that appear to be way less than an hour of labor, do dealers get mad about waiters (waiting in the lobby) rather than screwing around with rides or a loaner?

 

[icegradner]

I've noticed a rattle from somewhere in the passenger area, and where the dash plastic curves around the instrument panel. Thought about just fixing the instrument stuff myself with black foam, but maybe I should have this whole service done.

Pretty dumb question as this is the first new vehicle I've personally owned with a warranty, how do you go about scheduling services for TSBs that are applicable to your vehicle, and for ones like this that appear to be way less than an hour of labor, do dealers get mad about waiters (waiting in the lobby) rather than screwing around with rides or a loaner?

For a TSB, it's best to call ahead and mention it. The service writer will then look it up and see if your VIN fits with the bulletin. If it does they will want to test drive the vehicle and do the repair if they think it's needed. I suspect it would take more than an hour to do the needed test drives and work.

 

[cyberdog]

Anyone else think those blocks appear to be the same size as the Ceramic Coat application blocks, which are made of urethane? - They also resemble a piece of Frost-King's thick window/door weather stripping, with the peelable paper backing. (I have both at the house and might just trying pushing one into the passenger side area this weekend).

Placement might explain why stuffing the foam backer-rod into the dash to glass gap seems to quiet most owners vehicles. It would essentially be placing a piece of foam against the upper edge of the same area.

 

[bgn]

I have the foam blocks on order and they just shipped out. They should be here by early next week.

 

[Nemo]

Cut a piece of kneeling pad to same dimensions. What a pain this is to install as it is almost impossible to reach with bigger hands. You have to remove the trim at the bottom of the steering wheel, otherwise, no way of reaching. There is the plastic duct which I thought this goes against, but the gap was way too big. This actually goes above that, there is a spot you can barely see at the top, against the glass/firewall. Cutting the beveled edge (I’m sure the kneeling pad is harder/thicker) helped a bunch and it fit right in. Will see how much it helps as it has gotten worse with the cold weather. I’m sure the techs are cussing left and right as they install this.

Edit: Not the miracle solution I was expecting it to be. Driver’s side still rattles, must be somewhere else.

 

[BuiltFordTough?]

I bought the part online but I couldn't find the extra piece to make it a little thicker. When I installed it the piece didn't fit too snug and the rattle was still present. I had some foam insulation for 1/2" copper pipe laying around in the garage so I cut a piece of it and placed it in the same spot shown in the video and my rattle is completely gone. The pipe insulation is cheap and can be found at Home Depot, Lowes and I think even Walmart.

 

[strydertortois]

Do you

Well, I spent the afternoon working on this TSB, and it is definitely an acrobatic art to get those foam blocks in place. Would have been better if Ford had noted the need for a special tool, specifically a teenaged basketball player with long skinny arms!

But the exercise did provide some insight on the problem. The creak/rattle is definitely caused by the 2 piece defroster duct design. The new foam block is pushing against the front piece (part of the IP) to hopefully tighten the gap with the back piece. It does help somewhat with the rattle, but not so much with the creaking since the pieces are still moving relative to each other.

I found the best way to reduce the creaking is to spray some dry lube like SailKote (used for sails on masts) into the duct gaps (from the top) to allow the plastic parts to slide against each other more easily. Not a perfect fix, but it helps with the creaking loudness.

There is no other real fix, aside from taking out the entire IP and placing felt on the rear duct piece where it rubs against the IP (should have been added by design in the first place). It might be accessible when the windshield is removed. The glass guys won’t be keen about you working on the vehicle during a windshield replacement, but the foam blocks will fall out anyway, so it could be an opportunity for a better fix.

Finally, from what I hear it seems this is more of a drivers side problem than passenger side, which is unfortunate since the drivers side duct is much harder to access, teenage basketball player tool not withstanding!

Do you know if this issue has been fixed on the 2025 MY? I have this issue on my 2024 and it’s incredibly annoying. Will try to get a dealership near me to do the TSB and we will see what happens. I found that shoving pieces of a credit card in between the vent and the IP on the drivers side helps but the rattle is still present.

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